Lighting assembly and methods of assembling same

Abstract

A lighting assembly is disclosed. The lighting assembly has an extrusion having a back plate and a plurality of fins. Each fin has a plurality of openings. The lighting assembly has at least one circuit board with a plurality of LEDs. The lighting assembly also has at least one lens holder. Each lens holder has a plurality of openings and a plurality of pockets. The plurality of openings of the lens holder are disposed to accommodate the plurality of LEDs when the lens holder is placed on top of the circuit board. Each of the plurality of pockets is used to accommodate placement of a corresponding lens. The plurality of LEDs are disposed, and the corresponding lenses are sized and disposed, to maximize light density over a given area.

What is claimed is: 
     
       1. A lighting assembly, comprising:
 an extrusion having:
 a back plate; and 
 a plurality of fins, each fin defining a plurality of openings, a number and a size of the plurality of openings on each fin shaped to increase heat dissipation; 
 
 at least one circuit board having a plurality of light emitting diodes; 
 lenses; 
 at least one lens holder having:
 a plurality of openings; and 
 a plurality of pockets, each of the plurality of pockets shaped to accommodate therein a corresponding one of the lenses; and 
 
 when the at least one circuit board and the at least one lens holder is installed at the extrusion with the at least one lens holder placed on top of the at least one circuit board, the plurality of openings of the at least one lens holder being disposed to accommodate and surround the plurality of light emitting diodes, and the plurality of light emitting diodes being disposed and the corresponding lenses being sized and disposed in a non-linear compact footprint to maximize light density over a given area of the at least one circuit board. 
 
     
     
       2. The lighting assembly of  claim 1 , wherein the plurality of fins comprise top fins and bottom fins. 
     
     
       3. The lighting assembly of  claim 2 , wherein the plurality of fins allow heat to dissipate over multiple axes. 
     
     
       4. The lighting assembly of  claim 1 , wherein the back plate comprises a heat sink. 
     
     
       5. The lighting assembly of  claim 1 , wherein the back plate has a plurality of openings. 
     
     
       6. The lighting assembly of  claim 5 , further comprising a control printed circuit board, the plurality of openings of the back plate comprising a first type of opening operable to permit connection between the at least one circuit board and the control printed circuit board. 
     
     
       7. The lighting assembly of  claim 6 , wherein:
 the control printed circuit board has a surface-mounted electrical connector; and 
 the at least one circuit board is connected to the control printed circuit board through the surface-mounted electrical connector. 
 
     
     
       8. The lighting assembly of  claim 5 , wherein the plurality of openings of the back plate comprises a second type of opening operable to permit attachment of the at least one circuit board and the at least one lens holder to the back plate. 
     
     
       9. The lighting assembly of  claim 1 , wherein the extrusion has sides and further comprising side plates attached to each of the sides of the extrusion. 
     
     
       10. The lighting assembly of  claim 9 , wherein the lighting assembly is ruggedized by using ruggedized side plates and steel through-rods to reinforce against vibration and shock. 
     
     
       11. The lighting assembly of  claim 1 , further comprising a male connector and a female connector operable to allow serial connection of one lighting assembly to another lighting assembly. 
     
     
       12. The lighting assembly of  claim 11 , further comprising a plurality of sets each comprising the extrusion, the at least one circuit board, the lenses, the at least one lens holder, the male connector and the female connector, the plurality of sets forming a modular assembly of lighting assemblies connected to one another by respective adjacent pairs of one male connector and one female connector in a serial connection.